Powder distributing apparatus



March 3, 1942. c. J. DAVIES POWDER DISTRIBUTING APPARATUS Filed April 15, 1940 3 Sheets-Sheet l INVENTOR CLARENCE J.DAVIE$ BY WW, ATTORNEYS March '3, 1942.

C. J. DAVIES POWDER DI STRIBUTING APPARATUS 3 Sheets-Sheet 2 Filed April 15, 1940 I III INVENTOR.

CLA ENGE J.DAVIE$ BY J ATTORNEYS March 3, 1942. c. J. DAVIES 2,274,952

POWDER DISTRIBUTING APPARATUS FlG.5.

- INVENTOR. CLARENCE J.DAVIE$ my ATTORNEYS Patented Mar. 3, 1942 POWDER DISTRIBUTING APPARATUS Clarence J. Davies, Detroit, Mich., assignor to National Automotive Fibres,

Inc., Detroit,

Mich., a corporation of Delaware Application April 15, 1940, Serial No. 329,769

2 Claims. (Cl. 91-18) The present invention relates to powder distributing apparatus and more particularly to apparatus for forming a fibrous batt having powder uniformly distributed therethrough.

In my prior copencling application Serial No. 323,430, entitled Sheet material, filed March 11, 1940, I have disclosed the method of making as a new product of manufacture a fibrous material having a binder uniformly distributed therethrough, in which the binder is substantially concentrated near the surface, and the surface is smoothed by an operation set forth in detail in said earlier application.

The present apparatus comprises means for building up or forming a continuous fibrous batt and for distributing powder uniformly therethrough. The powder, as set forth in my prior application referred to above, is preferably a resin or similar material adapted upon heating to soften and to reset upon cooling.

Briefly described, according to the present invention, the continuous batt of fibrous material is built up by means of a Garnett in which a thin film of cotton is generated by means of a picker and is fed by suitable conveyors to a cross lapper. The cross lapper is adapted to deposit the film of fibrous material on an advancing conveyor and it is reciprocated back and forth across the conveyor so that the film of fibrous material is built up into a plurality of later-v ally overlapping folds, thus forming a batt of the desired thickness. Obviously, of course, a plurality of Garnetts may be employed in conjunction with a single floor apron, but in the present application I have illustrated and described a single Garnett. If more than one is used, the apparatus disclosed herein is merely duplicated.

Means are provided for depositing powdered material on the thin film of fibrous material as it is generated, or shortly thereafter. The film of fibrous material at this time is very thin and the powdered material seeps down into the fibrous material to some extent. However, in the completed continuous batt it is found that the powdered material has a tendency to be present in strata so that the fibrous batt comprises alternate layers of fibrous material and layers of powder.

In the product previously referred to it is quite important that the distribution of powder through the fibrous material shall be substantially uniform. Accordingly I have devised the present apparatus for insuring uniformity of distribution of powdered material. This apparatus takes the form of means for progressively compressing the batt in such a way as to force entrapped air longitudinally therethrough. The movement of the entrapped air longitudinally of the batt is effective to distribute the powdered material uniformly therethrough, and the mechanical compression which accompanies the process is also instrumental in rendering uniform the distribution of powder.

The apparatus for performing the aforesaid functions comprises essentially a lower supporting conveyor, preferably inclined substantially from the horizontal, over which the stratified fibrous batt is advanced. A second conveyor is provided overlying the fibrous batt. This conveyor is in the form of a flexible belt adapted to contact the upper surface of the fibrous material and to move synchronously therewith. Means are provided adjacent the portion of the upper flexible belt which contacts the upper surface of the fibrous material, and this means is adapted to compress the fibrous material, a substantial amount progressively, and preferably the progression of compression moves in a direction opposite to the advance of the fibrous material. This last means may conveniently take the form of one or a plurality of rollers, and means are provided for moving the rollers in pressure contact with the upper flexible belt opposite to the direction of travel of the fibrous material at a rate substantially greater than the rate of advance of fibrous material. Thi has the effect of forcing entrapped air longitudinally through the fibrous batt and rendering uniform the distribution of powdered material as aforesaid.

With the foregoing general remarks in view, it is an object of the present invention to provide means for generating a fibrous batt and for providing uniform distribution of a powdered material therethrough.

It is a further objectof the present invention to provide apparatus for rendering uniform a non-uniform distribution of powdered material throughout a fibrous batt.

It is a further object of the present invention to provide apparatus for rendering uniform a non-uniform distribution of powdered material in a fibrous batt which comprises means for progressively compressing the fibrous batt in a manner to displace entrapped air longitudinally therethrough.

It is a further object of the present invention to provide apparatus of the character described characterized by the use of a flexible impervious sheet material adapted to overlie a fibrous batt in combination with means for progressively moving the sheet material in a manner to compress a fibrous batt.

Other objects of the invention will be apparent as the description proceeds, and when taken in conjunction with the accompanying drawings wherein:

Figure 1 is a diagrammatic view of a Garnett equipped with means for distributing powder on a film of generated fibrous material;

Figure 2 is a side elevation of the apparatus for rendering uniform the distribution of powder;

Figure 3 is a fragmentary top view of the rear of the machine shown in Figure 2 taken in the direction of the arrows 33 of Figure 2;

Figure 4 is a fragmentary top plan view of the front side of the apparatus shown in Figure 2 taken in the direction of the arrows 4-4 of Figure 2; and

Figure 5 is a section on the line 5-5 of Figure 2.

Referring first to Figure 1, I have illustrated a Garnett machine of the type adapted to generate a batt of fibrous material indicated at III which comprises a frame having uprights l I and I2 and cross members I3. Intermediate the uprights II and I2 is a conveyor or floor apron It mounted on rollers I5 carried by the uprights I I and I2. A cross lapper carriage I6 is mounted for reciprocation back and forth across the cross pieces I3, suitable rollers II being provided. The carriage l5 has a depending portion I8 which in turn carries a pair of rollers I9 and 25!, and a pair of upper rollers 2| and 22.

A very thin film of fibrous material is generated from a roll 23 and is picked from the roll by a picker 24, whence it is fed across a feed roll 25 on to a conveyor 26 carried by rolls 21' and 28'. After the thin film of fibrous material has been removed from th roll 23, powdered material is distributed thereon by suitable means, and I have indicated diagrammatically at 29 one such means. This may take the form of a receptacle for powdered material provided with a perforated bottom in combination with means for continuously causing powdered material to be sifted downwardly through the perforations. The details of'the sifting device form no part of the present invention and many'suitable devices for this purpos are available. a

A second conveyor 30 mounted between rolls 3| and 32- is adapted to receive the film of fibrous material indicated at 33 and to advance the same toward the cross lapper carriage. A pair of conveyors 34 and 35 are provided extending over upper rolls 3:6 and 31, respectively, and are arranged to advance the thin film of fibrous material downwardly therebetween. The lower ends of the conveyors 34 and 35 are carried by the rolls 22 and 2| previously referred to.

Suitable mechanism is provided for causing the carriage 22 to reciprocate back and forth across the floor apron I4, and this means is diagrammatically indicated in Figure 1. A drive pulley 4D is provided having a belt 4i and a cross belt 62 adapted to r'eversely drive a shaft 43 having pulleys M" thereon. A shifting fork is indicated at- 45 and is adapted to be actuated responsive to reciprocation of the carriage I 6. Means for causing shifting of the shifting fork 45 includes a rod 46 having stops 4'! and 48 thereon. When the carriage It engages one of the stops it shifts the rod 46 which is connected by suitable linkage 49 with the shifter fork 45.

The floor apron is advanced continuously at a slow rate relative to the reciprocation of the carriage l6 so that the thin fibrous web is folded into a plurality of transversely overlapping folds. Obviously the thickness of the completed batt I0 depends upon the rate of advance of the fioor apron I4.

Referring now to Figure 2, I have illustrated the side elevation of the apparatus for rendering uniform the non-uniform distribution of the powdered material in the fibrous batt III. This means comprises a fram having uprights 62 and GI which are herein illustrated as being formed of angle iron. Spanning the uprights 60 and 6|, and at a substantial angle to the horizontal, are frame elements 62. Carried on the inclined frame element 62 are rollers 63 mounted in suitable brackets 64, one of which is illustrated as being adjustable by adjusting means 65 for the purpose of varying the tension in a conveyor belt 66. Also carried by the cross piece 62 is a fiat supporting member 6! over the upper surface of which the conveyor belt I56 moves. The support 61 is carried from the inclined frame member 62 by suitable supporting means 62, which may be angle irons or the like.

The lower run of the conveyor belt 26 advances between plates I9 and II suitably supported from the inclined frame member $2. As indicated in Figure 2, the plates I53 and 'II have curved ends 12 and 13, respectively, curved away from the conveyor belt.

The balance of the structure is adjustably carried from the frame structure thus far described and comprises longitudinal frame members 86] connected by suitable cross members in conjunction with relatively long frame members 8i extending substantially perpendicular to the frame members 86. Brace members 82 interconnect'members and 8| as seen in Figure 2. The structure comprising frame members 80, 8i and 82 is supported from the lower frame by means which will now be described. Brackets 85 are bolted or otherwise secured to the inclined frame members 62 and are provided with recesses 86. Within the recesses ar rotatably positioned threaded studs 81 having keyed or otherwise secured thereto a nut-like member 88. The member- 38 is adapted to be gripped by a wrench or suitable tool and rotated thereby, rotating the threaded studs 81. Secured on the underside of frame members 80 ar depending internally threaded projections in which the studs 81 are threaded, suitable lock nuts 9i being provided. In order to adjust the upper frame toward the lower frame, it is necessary only to loosen the lock nut SI and then to rotate the member 88, thus rotatin the threaded stud and efi'ecting adjustment of the upper frame relative to the lower. The stud 8.! is mounted for free rotation in the bracket 85 as. previously described.

Carried by the upper frame are rollers I III], IIJI and I132. The rollers I00 and I02, as indicated, are secured directly to the inclined frame members 80, whereas the roller IIJI is carried by an adjustable support I83 on the frame member BI. These rollers have a flexible conveyor belt IIM carried thereby, and in order to tighten the belt IM, adjusting means indicated generally at I05 are provided for the adjustable support I03. Intermediate the rollers IBI and I02 I provide a movable frame portion IIEl which is retained in adjusted position by means of a locknut [I I associated with an elongated slot H2 carried by a supporting bracket H3. Frame members H0 have secured thereto a fiat plate II4 having a curved edge H5 and an oppositely disposed plate IIB having a curved edge I. The conveyor belt I04 is adapted to pass between the plates H6 and H4.

The frame member 82 has secured thereto a bracket I20 having a sprocket I2I' mounted thereon and a drive chain I 22 passes over the sprocket I2 I. I have indicated a second sprocket I23 which is associated with the main frame and may have suitable driving means connected therewith. The roller 63 is mounted on a shaft I24 which has a driving sprocket I25 keyed or otherwise secured thereto. The roller I previously referred to is mounted on a shaft I26 and a sprocket I2I is keyed or otherwise secured to this shaft. The chain I22 passes around sprockets I2I, I23, I25 and I2'I. The sprockets I25 and I21 and the rollers I00 and 63 are the same size so that the conveyor belts 6B and I04 are driven at the same speed. Also due to the relationship of the chain I22 to the sprockets I25 and I21,- the lower run of the belt I04 moves in the same direction and synchronously with the upper run of the conveyor belt 66.

Mounted on the upper frame and carried by the frame members 80 are a pair of brackets I30 carrying sprockets I 3|. A chain I32 extends between the sprockets I3I and mounted on the chain are extending supporting members I33 adapted to support a roller I34 therebetween. In Figure 2 I have illustrated two such rollers, although one or any number may be provided. The rollers I34 are adapted to extend completely across the conveyor for a purpose which will subsequently be described.

Carried by the upper frame and mounted on a frame member BI is an independent driving motor I40. The rotor of this motor has keyed or otherwise secured thereto a pinion I4I which engages a gear I42 carried by a shaft I43 which is carried by a bracket I44 formed on a supporting plate I45, as best seen in Figure 4. Also carried by the shaft I43 is a smaller sprocket I46 adapted to drive a chain I4'I which in turn drives a sprocket I40 carried by a shaft I49, which in turn supports the sprocket I3I previously referred to. The direction of rotation of the chain I32 is such as to cause the rollers I34 to move in the direction of the arrow I59. Preferably the chain I32 is driven at a relatively high speed, and by way of example excellent results have been obtained when this speed has been approximately 150 feet a minute. It will be observed that the roller I34 is adapted to contact the upper surface of the belt I04 and to move the same in a manner to compress the fibrous material III which is being advanced by the conveyor belt 66. Furthermore, the flat support 61 previously defined supports the conveyor belt '56, to render this compression effective. As the fibrous material I0 is advanced upwardly along the inclined support 61 the roller or rollers I34 move relatively rapidly down the incline in a manner to cause rapid displacement of entrapped air along the batt. Furthermore the mechanical displacement of the fibrous material by the roller or rollers I34 is also effective to assist in rendering uniform the distribution of powdered material. Since as above stated the operation is effective to rapidly displace entrapped air along the batt, the belts Iifiand I04 are substantially impervious to air.

Referring now particularly to Figure 5, means are provided for holding the chain in a straight line intermediate the sprockets I3I. This means comprises a bar I carried by a bracket I6I secured to cross pieces I62 which are supported from the inclined frame member 80 by means of blocks I64 positioned intermediate frame members 80 and cross pieces I62. In Figure 5 I have indicated a bolt I65 as securing the cross piece I62 to the frame member through the medium of the blocks I64.

By this arrangement the rollers I34 are caused to move in a straight line while in contact with the upper belt I04 and to compress the fibrous material I0 therebeneath uniformly.

The foregoing apparatus is adapted to fabricate a continuous batt of fibrous material having a powdered material substantially uniformly distributed therethrough. It may be mentioned that the powdered material is preferably a thermoplastic resin, and the further processing of the material comprises the steps of heating the thermoplastic powder to soften the same and then to cause the same to set, thereby binding the fibers of the batt together.

While I have illustrated a single embodiment of the machine, it will be understood that this has been done solely to enable those skilled in the art to practice the invention the scope of which is indicated by the appended claims.

What I claim as my invention is:

l. A substantially impervious support for a batt of fibrous material, a flexible, substantially impervious cover adapted to rest on fibrous material carried by said support, and means engaging said cover and relatively movable parallel thereto for progressively compressing said fibrous material between'said cover and support in a manher to displace entrapped air along said fibrous material.

2. Apparatus of the character described, comprising an inclined support, a substantially impervious conveyor movable along said support, a flexible, substantially impervious belt having a length movable parallel to and synchronously with said conveyor, a roller engaging said belt and adapted to hold a portion of said belt in closely spaced relation to said conveyor, and means for moving said roller rapidly along said belt in a direction opposite to the direction of advance of said belt.

CLARENCE J. DAVIES. 

